Production of acrylic acid from a methane conversion process

ABSTRACT

Methods and systems are provided for converting methane in a feed stream to acetylene. The method includes processing the acetylene to form a stream having acrylic acid. The hydrocarbon stream is introduced into a supersonic reactor and pyrolyzed to convert at least a portion of the methane to acetylene. The reactor effluent stream is be treated to convert acetylene to acrylic acid. The method according to certain aspects includes controlling the level of carbon monoxide to prevent undesired reactions in downstream processing units.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Division of prior copending U.S. application Ser.No. 13/915,159 which was filed on Jun. 11, 2013, which is incorporatedherein by reference in its entirety and which claims priority fromProvisional Application No. 61/691,362 filed Aug. 21, 2012.

FIELD OF THE INVENTION

A process is disclosed for producing chemicals useful for the productionof polymers from the conversion of methane to acetylene using asupersonic flow reactor. More particularly, the process is for theproduction of acrylic acid.

BACKGROUND OF THE INVENTION

The use of plastics and rubbers are widespread in today's world. Theproduction of these plastics and rubbers are from the polymerization ofmonomers which are generally produced from petroleum. The monomers aregenerated by the breakdown of larger molecules to smaller moleculeswhich can be modified. The monomers are then reacted to generate largermolecules comprising chains of the monomers. An important example ofthese monomers are light olefins, including ethylene and propylene,which represent a large portion of the worldwide demand in thepetrochemical industry. Light olefins, and other monomers, are used inthe production of numerous chemical products via polymerization,oligomerization, alkylation and other well-known chemical reactions.Producing large quantities of light olefin material in an economicalmanner, therefore, is a focus in the petrochemical industry. Thesemonomers are essential building blocks for the modern petrochemical andchemical industries. The main source for these materials in present dayrefining is the steam cracking of petroleum feeds.

A principal means of production is the cracking of hydrocarbons broughtabout by heating a feedstock material in a furnace has long been used toproduce useful products, including for example, olefin products. Forexample, ethylene, which is among the more important products in thechemical industry, can be produced by the pyrolysis of feedstocksranging from light paraffins, such as ethane and propane, to heavierfractions such as naphtha. Typically, the lighter feedstocks producehigher ethylene yields (50-55% for ethane compared to 25-30% fornaphtha); however, the cost of the feedstock is more likely to determinewhich is used. Historically, naphtha cracking has provided the largestsource of ethylene, followed by ethane and propane pyrolysis, cracking,or dehydrogenation. Due to the large demand for ethylene and other lightolefinic materials, however, the cost of these traditional feeds hassteadily increased.

Energy consumption is another cost factor impacting the pyrolyticproduction of chemical products from various feedstocks. Over the pastseveral decades, there have been significant improvements in theefficiency of the pyrolysis process that have reduced the costs ofproduction. In a typical or conventional pyrolysis plant, a feedstockpasses through a plurality of heat exchanger tubes where it is heatedexternally to a pyrolysis temperature by the combustion products of fueloil or natural gas and air. One of the more important steps taken tominimize production costs has been the reduction of the residence timefor a feedstock in the heat exchanger tubes of a pyrolysis furnace.Reduction of the residence time increases the yield of the desiredproduct while reducing the production of heavier by-products that tendto foul the pyrolysis tube walls. However, there is little room left toimprove the residence times or overall energy consumption in traditionalpyrolysis processes.

More recent attempts to decrease light olefin production costs includeutilizing alternative processes and/or feedstreams. In one approach,hydrocarbon oxygenates and more specifically methanol or dimethylether(DME) are used as an alternative feedstock for producing light olefinproducts. Oxygenates can be produced from available materials such ascoal, natural gas, recycled plastics, various carbon waste streams fromindustry and various products and by-products from the agriculturalindustry. Making methanol and other oxygenates from these types of rawmaterials is well established and typically includes one or moregenerally known processes such as the manufacture of synthesis gas usinga nickel or cobalt catalyst in a steam reforming step followed by amethanol synthesis step at relatively high pressure using a copper-basedcatalyst.

Once the oxygenates are formed, the process includes catalyticallyconverting the oxygenates, such as methanol, into the desired lightolefin products in an oxygenate to olefin (OTO) process. Techniques forconverting oxygenates, such as methanol to light olefins (MTO), aredescribed in U.S. Pat. No. 4,387,263, which discloses a process thatutilizes a catalytic conversion zone containing a zeolitic typecatalyst. U.S. Pat. No. 4,587,373 discloses using a zeolitic catalystlike ZSM-5 for purposes of making light olefins. U.S. Pat. Nos.5,095,163; 5,126,308 and 5,191,141 on the other hand, disclose an MTOconversion technology utilizing a non-zeolitic molecular sieve catalyticmaterial, such as a metal aluminophosphate (ELAPO) molecular sieve. OTOand MTO processes, while useful, utilize an indirect process for forminga desired hydrocarbon product by first converting a feed to an oxygenateand subsequently converting the oxygenate to the hydrocarbon product.This indirect route of production is often associated with energy andcost penalties, often reducing the advantage gained by using a lessexpensive feed material. In addition, some oxygenates, such as vinylacetate or acrylic acid, are also useful chemicals and can be used aspolymer building blocks.

Recently, attempts have been made to use pyrolysis to convert naturalgas to ethylene. U.S. Pat. No. 7,183,451 discloses heating natural gasto a temperature at which a fraction is converted to hydrogen and ahydrocarbon product such as acetylene or ethylene. The product stream isthen quenched to stop further reaction and subsequently reacted in thepresence of a catalyst to form liquids to be transported. The liquidsultimately produced include naphtha, gasoline, or diesel. While thismethod may be effective for converting a portion of natural gas toacetylene or ethylene, it is estimated that this approach will provideonly about a 40% yield of acetylene from a methane feed stream. While ithas been identified that higher temperatures in conjunction with shortresidence times can increase the yield, technical limitations preventfurther improvement to this process in this regard.

While the foregoing traditional pyrolysis systems provide solutions forconverting ethane and propane into other useful hydrocarbon products,they have proven either ineffective or uneconomical for convertingmethane into these other products, such as, for example ethylene. WhileMTO technology is promising, these processes can be expensive due to theindirect approach of forming the desired product. Due to continuedincreases in the price of feeds for traditional processes, such asethane and naphtha, and the abundant supply and corresponding low costof natural gas and other methane sources available, for example the morerecent accessibility of shale gas, it is desirable to providecommercially feasible and cost effective ways to use methane as a feedfor producing ethylene and other useful hydrocarbons.

SUMMARY

A method for producing acetylene according to one aspect is provided.The method generally includes introducing a feed stream portion of ahydrocarbon stream including methane into a supersonic reactor. Themethod also includes pyrolyzing the methane in the supersonic reactor toform a reactor effluent stream portion of the hydrocarbon streamincluding acetylene. The method further includes treating at least aportion of the hydrocarbon stream in a process for producing highervalue products, such as acrylic acid. Acrylic acid is a precursor toforming plastics such as poly methyl methacrylate.

The present invention comprises converting methane to acetylene througha supersonic reaction that generates conditions for the pyrolysisreaction. The acetylene is converted to propylene throughhydroprocessing. The hydroprocessing can include hydrogenation toethylene, with subsequent dimerization, or oligomerization to higherolefins, and further processing to convert ethylene and higher olefinsto propylene through metathesis reactions or olefin cracking processes.The propylene stream is oxidized to convert the propylene to eitheracrylic acid, or to convert the propylene to acrolein with subsequentconversion to acrylic acid.

In one embodiment, the present invention utilizes the acetylene andcarbon monoxide effluent stream generated by the supersonic reactordirectly. The effluent stream is passed with steam to an acrylic acidreactor under high pressure to generate an acrylic acid effluent stream.

Other objects, advantages and applications of the present invention willbecome apparent to those skilled in the art from the following detaileddescription and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side cross-sectional view of a supersonic reactor inaccordance with various embodiments described herein; and

FIG. 2 is a schematic view of a system for converting methane intoacetylene and other hydrocarbon products in accordance with variousembodiments described herein.

DETAILED DESCRIPTION

One proposed alternative to the previous methods of producinghydrocarbon products that has not gained much commercial tractionincludes passing a hydrocarbon feedstock into a supersonic reactor andaccelerating it to supersonic speed to provide kinetic energy that canbe transformed into heat to enable an endothermic pyrolysis reaction tooccur. Variations of this process are set out in U.S. Pat. Nos.4,136,015 and 4,724,272, and Russian Patent No. SU 392723A. Theseprocesses include combusting a feedstock or carrier fluid in anoxygen-rich environment to increase the temperature of the feed andaccelerate the feed to supersonic speeds. A shock wave is created withinthe reactor to initiate pyrolysis or cracking of the feed. Inparticular, the hydrocarbon feed to the reactor comprises a methanefeed. The methane feed is reacted to generate an intermediate processstream which is then further processed to generate a hydrocarbon productstream. A particular hydrocarbon product stream of interest is acrylicacid.

More recently, U.S. Pat. Nos. 5,219,530 and 5,300,216 have suggested asimilar process that utilizes a shock wave reactor to provide kineticenergy for initiating pyrolysis of natural gas to produce acetylene.More particularly, this process includes passing steam through a heatersection to become superheated and accelerated to a nearly supersonicspeed. The heated fluid is conveyed to a nozzle which acts to expand thecarrier fluid to a supersonic speed and lower temperature. An ethanefeedstock is passed through a compressor and heater and injected bynozzles to mix with the supersonic carrier fluid to turbulently mixtogether at a Mach 2.8 speed and a temperature of about 427° C. Thetemperature in the mixing section remains low enough to restrictpremature pyrolysis. The shockwave reactor includes a pyrolysis sectionwith a gradually increasing cross-sectional area where a standing shockwave is formed by back pressure in the reactor due to flow restrictionat the outlet. The shock wave rapidly decreases the speed of the fluid,correspondingly rapidly increasing the temperature of the mixture byconverting the kinetic energy into heat. This immediately initiatespyrolysis of the ethane feedstock to convert it to other products. Aquench heat exchanger then receives the pyrolized mixture to quench thepyrolysis reaction.

Methods and systems for converting hydrocarbon components in methanefeed streams using a supersonic reactor are generally disclosed. As usedherein, the term “methane feed stream” includes any feed streamcomprising methane. The methane feed streams provided for processing inthe supersonic reactor generally include methane and form at least aportion of a process stream that includes at least one contaminant. Themethods and systems presented herein remove or convert the contaminantin the process stream and convert at least a portion of the methane to adesired product hydrocarbon compound to produce a product stream havinga reduced contaminant level and a higher concentration of the producthydrocarbon compound relative to the feed stream. By one approach, ahydrocarbon stream portion of the process stream includes thecontaminant and methods and systems presented herein remove or convertthe contaminant in the hydrocarbon stream.

The term “hydrocarbon stream” as used herein refers to one or morestreams that provide at least a portion of the methane feed streamentering the supersonic reactor as described herein or are produced fromthe supersonic reactor from the methane feed stream, regardless ofwhether further treatment or processing is conducted on such hydrocarbonstream. The “hydrocarbon stream” may include the methane feed stream, asupersonic reactor effluent stream, a desired product stream exiting adownstream hydrocarbon conversion process or any intermediate orby-product streams formed during the processes described herein. Thehydrocarbon stream may be carried via a process stream line 115, whichincludes lines for carrying each of the portions of the process streamdescribed above. The term “process stream” as used herein includes the“hydrocarbon stream” as described above, as well as it may include acarrier fluid stream, a fuel stream, an oxygen source stream, or anystreams used in the systems and the processes described herein. Theprocess stream may be carried via a process stream line 115, whichincludes lines for carrying each of the portions of the process streamdescribed above.

Prior attempts to convert light paraffin or alkane feed streams,including ethane and propane feed streams, to other hydrocarbons usingsupersonic flow reactors have shown promise in providing higher yieldsof desired products from a particular feed stream than other moretraditional pyrolysis systems. Specifically, the ability of these typesof processes to provide very high reaction temperatures with very shortassociated residence times offers significant improvement overtraditional pyrolysis processes. It has more recently been realized thatthese processes may also be able to convert methane to acetylene andother useful hydrocarbons, whereas more traditional pyrolysis processeswere incapable or inefficient for such conversions.

The majority of previous work with supersonic reactor systems, however,has been theoretical or research based, and thus has not addressedproblems associated with practicing the process on a commercial scale.In addition, many of these prior disclosures do not contemplate usingsupersonic reactors to effectuate pyrolysis of a methane feed stream,and tend to focus primarily on the pyrolysis of ethane and propane. Oneproblem that has recently been identified with adopting the use of asupersonic flow reactor for light alkane pyrolysis, and morespecifically the pyrolysis of methane feeds to form acetylene and otheruseful products therefrom, includes negative effects that particularcontaminants in commercial feed streams can create on these processesand/or the products produced therefrom. Previous work has not consideredthe need for product purity, especially in light of potential downstreamprocessing of the reactor effluent stream. Product purity can includethe separation of several products into separate process streams, andcan also include treatments for removal of contaminants that can affecta downstream reaction, and downstream equipment.

In accordance with various embodiments disclosed herein, therefore,processes and systems for converting the methane to a product stream arepresented. The methane is converted to an intermediate process streamcomprising acetylene. The intermediate process stream is converted to asecond process stream comprising either a hydrocarbon product, or asecond intermediate hydrocarbon compound. The processing of theintermediate acetylene stream can include purification or separation ofacetylene from by-products.

The removal of particular contaminants and/or the conversion ofcontaminants into less deleterious compounds has been identified toimprove the overall process for the pyrolysis of light alkane feeds,including methane feeds, to acetylene and other useful products. In someinstances, removing these compounds from the hydrocarbon or processstream has been identified to improve the performance and functioning ofthe supersonic flow reactor and other equipment and processes within thesystem. Removing these contaminants from hydrocarbon or process streamshas also been found to reduce poisoning of downstream catalysts andadsorbents used in the process to convert acetylene produced by thesupersonic reactor into other useful hydrocarbons, for examplehydrogenation catalysts that may be used to convert acetylene intoethylene. Still further, removing certain contaminants from ahydrocarbon or process stream as set forth herein may facilitate meetingproduct specifications.

In accordance with one approach, the processes and systems disclosedherein are used to treat a hydrocarbon process stream, to remove acontaminant therefrom and convert at least a portion of methane toacetylene. The hydrocarbon process stream described herein includes themethane feed stream provided to the system, which includes methane andmay also include ethane or propane. The methane feed stream may alsoinclude combinations of methane, ethane, and propane at variousconcentrations and may also include other hydrocarbon compounds. In oneapproach, the hydrocarbon feed stream includes natural gas. The naturalgas may be provided from a variety of sources including, but not limitedto, gas fields, oil fields, coal fields, fracking of shale fields,biomass, and landfill gas. In another approach, the methane feed streamcan include a stream from another portion of a refinery or processingplant. For example, light alkanes, including methane, are oftenseparated during processing of crude oil into various products and amethane feed stream may be provided from one of these sources. Thesestreams may be provided from the same refinery or different refinery orfrom a refinery off gas. The methane feed stream may include a streamfrom combinations of different sources as well.

In accordance with the processes and systems described herein, a methanefeed stream may be provided from a remote location or at the location orlocations of the systems and methods described herein. For example,while the methane feed stream source may be located at the same refineryor processing plant where the processes and systems are carried out,such as from production from another on-site hydrocarbon conversionprocess or a local natural gas field, the methane feed stream may beprovided from a remote source via pipelines or other transportationmethods. For example a feed stream may be provided from a remotehydrocarbon processing plant or refinery or a remote natural gas field,and provided as a feed to the systems and processes described herein.Initial processing of a methane stream may occur at the remote source toremove certain contaminants from the methane feed stream. Where suchinitial processing occurs, it may be considered part of the systems andprocesses described herein, or it may occur upstream of the systems andprocesses described herein. Thus, the methane feed stream provided forthe systems and processes described herein may have varying levels ofcontaminants depending on whether initial processing occurs upstreamthereof.

In one example, the methane feed stream has a methane content rangingfrom about 65 mol-% to about 100 mol-%. In another example, theconcentration of methane in the hydrocarbon feed ranges from about 80mol-% to about 100 mol-% of the hydrocarbon feed. In yet anotherexample, the concentration of methane ranges from about 90 mol-% toabout 100 mol-% of the hydrocarbon feed.

In one example, the concentration of ethane in the methane feed rangesfrom about 0 mol-% to about 35 mol-% and in another example from about 0mol-% to about 10 mol-%. In one example, the concentration of propane inthe methane feed ranges from about 0 mol-% to about 5 mol-% and inanother example from about 0 mol-% to about 1 mol-%.

The methane feed stream may also include heavy hydrocarbons, such asaromatics, paraffinic, olefinic, and naphthenic hydrocarbons. Theseheavy hydrocarbons if present will likely be present at concentrationsof between about 0 mol-% and about 100 mol-%. In another example, theymay be present at concentrations of between about 0 mol-% and 10 mol-%and may be present at between about 0 mol-% and 2 mol-%.

In one embodiment, the invention comprises the conversion of methane toacrylic acid. The methane is passed to a supersonic reactor where itundergoes a pyrolysis reaction to generate an effluent stream comprisingacetylene. The acetylene is passed to a hydrogenation reactor operatedat hydrogenation conditions to form an ethylene stream. The ethylenestream is passed to a higher olefin processing unit to convert theethylene to an effluent stream comprising propylene. The propylene isthen passed to an acrylic acid reactor, along with an oxygen richstream, to generate an acrylic acid effluent stream. The process canfurther include passing steam to the acrylic acid reactor.

The higher olefin processing unit can comprise a dimerization reactorand a metatheis reactor, or comprise other hydroprocessing units toconvert the acetylene and/or ethylene to propylene. Propylene productioncan also include oligomerization reactors and olefin cracking units.

In one embodiment, the process of forming acrylic acid comprises passingthe propylene as generated by one of the means above to an aldehydereactor. The aldehyde reactor is operated at reaction conditions convertthe propylene to an effluent stream comprising acrolein. The acroleinprocess stream is passed with an oxygen stream to an acrylic acidreactor to convert the acrolein and generate an effluent streamcomprising acrylic acid.

The aldehyde reaction conditions include contacting the propylene with acatalyst, wherein the catalyst comprises a catalytic metal or metaloxide on a support. Catalytic metals are selected from bismuth (Bi),molybdenum (Mo), cobalt (Co), iron (Fe), copper (Cu), Raney nickel (Ni),zinc oxide (ZnO), and mixtures thereof. The catalyst can further includean alkali metal selected from potassium (K), sodium (Na), and mixturesthereof.

Aldehyde reaction conditions can also include the presence of stream,and is operated at a temperature between 150° C. and 500° C.

In one embodiment, the process comprises passing the process stream fromthe supersonic reactor to an acrylic acid reactor. The carbon monoxidein the process stream with the acetylene is reacted over a catalyst withsteam under high pressure to form acrylic acid. A catalyst useful inthis embodiment is a nickel bromide (NiBr) catalyst, or a nickelcarbonyl catalyst. The pressure is greater than 1 MPa.

Hydrogenation reactors comprise a hydrogenation catalyst, and areoperated at hydrogenation conditions to hydrogenate unsaturatedhydrocarbons. Hydrogenation catalysts typically comprise a hydrogenationmetal on a support, wherein the hydrogenation metal is preferablyselected from a Group VIII metal in an amount between 0.01 and 2 wt. %of the catalyst. Preferably the metal is platinum (Pt), palladium (Pd),or a mixture thereof. The support may be a solid acid molecular sieve,and can include zeolites such as zeolite beta, MCM-22, MCM-36,mordenite, faujasites such as X-zeolites and Y-zeolites, includingB—Y-zeolites and USY-zeolites; non-zeolitic solids such assilica-alumina, sulfated oxides such as sulfated oxides of zirconium,titanium, or tin, mixed oxides of zirconium, molybdenum, tungsten,phosphorus and chlorinated aluminium oxides or clays. Preferred solidacids are zeolites, including mordenite, zeolite beta, faujasites suchas X-zeolites and Y-zeolites, including BY-zeolites and USY-zeolites.Mixtures of solid supports can also be employed. In another embodiment,the catalyst support comprises at least one oxide of magnesium,aluminum, silicon, titanium, zinc, zirconium, used alone or as amixture, or with oxides of other elements from the periodic table,carbon, silico-aluminates, or clay. The support may be further modifiedwith Periodic Table IUPAC Group 1 or Group 2 elements. Examples ofadditional suitable catalyst supports include magnesium and nickelspinels.

In one embodiment, the present invention generates larger olefins. Thehydroprocessing effluent stream is passed to a second reactor. Thesecond reactor can include a dimerization reactor for generatingbutenes, an oligomerization reactor for generating larger olefins, andother reactors. The oligomerization process is operated to generateolefins in the C6 to C10 range, and in particular, the process isoperated to generate C6 and C8 olefins, and preferable 1-hexene and1-octene. The oligomerization catalysts can comprise any oligomerizationcatalyst, with preferred oligomerization catalysts comprisingorganometallic catalyst. The organometallic catalysts preferablycomprise a metal bonded to more than 1 organic ligand.

In one embodiment, the present invention is directed to generatingpropylene. A first portion of the hydroprocessing effluent stream ispassed to a dimerization reactor to generate a dimerization effluentcomprising butene. The dimerization effluent and a second portion of thehydroprocessing effluent stream is passed to a metathesis reactor forconverting the ethylene and butenes to generate a metathesis effluentstream comprising propylene. The metathesis effluent stream can bepassed to the light olefins recovery unit to generate an ethyleneproduct stream, a propylene product stream and a heavies stream forrecycle.

Catalysts which are active for the metathesis of olefins and which canbe used in the process of this invention are of a generally known type.In this regard, reference is made to JOURNAL OF CATALYSIS, 13 (1969)pages 99-114, to APPLIED CATALYSIS, 10 (1984) pages 29-229 and toCATALYSIS REVIEW, 3 (1) (1969) pages 37-60.

In another embodiment, the present invention is directed to generatinglarger olefins having 5 or more carbon atoms. The hydroprocessing streamcomprising ethylene is passed to an oligomerization reactor, where thereactor has an oligomerization catalyst and is operated atoligomerization conditions to generate an oligomerization effluentstream comprising olefins having 5 or more carbon atoms. Theoligomerization effluent stream is passed to an olefins recovery unitfor separation of the different olefins. The olefins recovery unit cancomprise multiple fractionation units, multiple adsorption separationunits, or some combination thereof for separating and recovering desiredolefins in olefin product streams, and recycling undesired olefins in arecycle stream.

In one embodiment, the process can include passing the oligomerizationeffluent stream to a light olefins recovery unit to generate a lightolefins product stream and a heavies stream comprising C4+ hydrocarbons.The heavies stream is passed to an olefin cracking unit to generatelight olefins, and the olefin cracking unit effluent is passed to thelight olefins recovery unit. This embodiment can also pass recyclestreams, comprising heavier olefins, from other processes to the olefincracking unit.

The process for forming acetylene from the methane feed stream describedherein utilizes a supersonic flow reactor for pyrolyzing methane in thefeed stream to form acetylene. The supersonic flow reactor may includeone or more reactors capable of creating a supersonic flow of a carrierfluid and the methane feed stream and expanding the carrier fluid toinitiate the pyrolysis reaction. In one approach, the process mayinclude a supersonic reactor as generally described in U.S. Pat. No.4,724,272, which is incorporated herein by reference, in their entirety.In another approach, the process and system may include a supersonicreactor such as described as a “shock wave” reactor in U.S. Pat. Nos.5,219,530 and 5,300,216, which are incorporated herein by reference, intheir entirety. In yet another approach, the supersonic reactordescribed as a “shock wave” reactor may include a reactor such asdescribed in “Supersonic Injection and Mixing in the Shock Wave Reactor”Robert G. Cerff, University of Washington Graduate School, 2010.

While a variety of supersonic reactors may be used in the presentprocess, an exemplary reactor 5 is illustrated in FIG. 1. Referring toFIG. 1, the supersonic reactor 5 includes a reactor vessel 10 generallydefining a reactor chamber 15. While the reactor 5 is illustrated as asingle reactor, it should be understood that it may be formed modularlyor as separate vessels. A combustion zone or chamber 25 is provided forcombusting a fuel to produce a carrier fluid with the desiredtemperature and flowrate. The reactor 5 may optionally include a carrierfluid inlet 20 for introducing a supplemental carrier fluid into thereactor. One or more fuel injectors 30 are provided for injecting acombustible fuel, for example hydrogen, into the combustion chamber 25.The same or other injectors may be provided for injecting an oxygensource into the combustion chamber 25 to facilitate combustion of thefuel. The fuel and oxygen are combusted to produce a hot carrier fluidstream typically having a temperature of from about 1200° C. to about3500° C. in one example, between about 2000° C. and about 3500° C. inanother example, and between about 2500° C. and 3200° C. in yet anotherexample. According to one example the carrier fluid stream has apressure of about 100 kPa or higher, greater than about 200 kPa inanother example, and greater than about 400 kPa in another example.

The hot carrier fluid stream from the combustion zone 25 is passedthrough a converging-diverging nozzle 50 to accelerate the flowrate ofthe carrier fluid to above about mach 1.0 in one example, between aboutmach 1.0 and mach 4.0 in another example, and between about mach 1.5 and3.5 in another example. In this regard, the residence time of the fluidin the reactor portion of the supersonic flow reactor is between about0.5 to 100 ms in one example, about 1 to 50 ms in another example, andabout 1.5 to 20 ms in another example.

A feedstock inlet 40 is provided for injecting the methane feed streaminto the reactor 5 to mix with the carrier fluid. The feedstock inlet 40may include one or more injectors 45 for injecting the feedstock intothe nozzle 50, a mixing zone 55, an expansion zone 60, or a reactionzone or chamber 65. The injector 45 may include a manifold, includingfor example a plurality of injection ports.

In one approach, the reactor 5 may include a mixing zone 55 for mixingof the carrier fluid and the feed stream. In another approach, no mixingzone is provided, and mixing may occur in the nozzle 50, expansion zone60, or reaction zone 65 of the reactor 5. An expansion zone 60 includesa diverging wall 70 to produce a rapid reduction in the velocity of thegases flowing therethrough, to convert the kinetic energy of the flowingfluid to thermal energy to further heat the stream to cause pyrolysis ofthe methane in the feed, which may occur in the expansion section 60and/or a downstream reaction section 65 of the reactor. The fluid isquickly quenched in a quench zone 72 to stop the pyrolysis reaction fromfurther conversion of the desired acetylene product to other compounds.Spray bars 75 may be used to introduce a quenching fluid, for examplewater or steam into the quench zone 72.

The reactor effluent exits the reactor via outlet 80 and as mentionedabove forms a portion of the hydrocarbon stream. The effluent willinclude a larger concentration of acetylene than the feed stream and areduced concentration of methane relative to the feed stream. Thereactor effluent stream may also be referred to herein as an acetylenestream as it includes an increased concentration of acetylene. Theacetylene may be an intermediate stream in a process to form anotherhydrocarbon product or it may be further processed and captured as anacetylene product stream. In one example, the reactor effluent streamhas an acetylene concentration prior to the addition of quenching fluidsranging from about 2 mol-% to about 30 mol-%. In another example, theconcentration of acetylene ranges from about 5 mol-% to about 25 mol-%and from about 8 mol-% to about 23 mol-% in another example.

In one example, the reactor effluent stream has a reduced methanecontent relative to the methane feed stream ranging from about 15 mol-%to about 95 mol-%. In another example, the concentration of methaneranges from about 40 mol-% to about 90 mol-% and from about 45 mol-% toabout 85 mol-% in another example.

The invention can include an acetylene enrichment unit having an inletin fluid communication with the reactor outlet, and an outlet for aacetylene enriched effluent. One aspect of the system can furtherinclude a contaminant removal zone having an inlet in fluidcommunication with the acetylene enrichment zone outlet, and an outletin fluid communication with the hydrocarbon conversion zone inlet, forremoving contaminants that can adversely affect downstream catalysts andprocesses. One contaminant to be removed is CO to a level of less than0.1 mole %, and preferably to a level of less than 100 ppm by vol.

An additional aspect of the invention is where the system can include asecond contaminant removal zone having an inlet in fluid communicationwith the methane feed stream and an outlet in fluid communication withthe supersonic reactor inlet.

In one example the yield of acetylene produced from methane in the feedin the supersonic reactor is between about 40% and about 95%. In anotherexample, the yield of acetylene produced from methane in the feed streamis between about 50% and about 90%. Advantageously, this provides abetter yield than the estimated 40% yield achieved from previous, moretraditional, pyrolysis approaches.

By one approach, the reactor effluent stream is reacted to form anotherhydrocarbon compound. In this regard, the reactor effluent portion ofthe hydrocarbon stream may be passed from the reactor outlet to adownstream hydrocarbon conversion process for further processing of thestream. While it should be understood that the reactor effluent streammay undergo several intermediate process steps, such as, for example,water removal, adsorption, and/or absorption to provide a concentratedacetylene stream, these intermediate steps will not be described indetail herein.

Referring to FIG. 2, the reactor effluent stream having a higherconcentration of acetylene may be passed to a downstream hydrocarbonconversion zone 100 where the acetylene may be converted to form anotherhydrocarbon product. The hydrocarbon conversion zone 100 may include ahydrocarbon conversion reactor 105 for converting the acetylene toanother hydrocarbon product. While FIG. 2 illustrates a process flowdiagram for converting at least a portion of the acetylene in theeffluent stream to ethylene through hydrogenation in hydrogenationreactor 110, it should be understood that the hydrocarbon conversionzone 100 may include a variety of other hydrocarbon conversion processesinstead of or in addition to a hydrogenation reactor 110, or acombination of hydrocarbon conversion processes. Similarly, itillustrated in FIG. 2 may be modified or removed and are shown forillustrative purposes and not intended to be limiting of the processesand systems described herein. Specifically, it has been identified thatseveral other hydrocarbon conversion processes, other than thosedisclosed in previous approaches, may be positioned downstream of thesupersonic reactor 5, including processes to convert the acetylene intoother hydrocarbons, including, but not limited to: alkenes, alkanes,methane, acrolein, acrylic acid, acrylates, acrylamide, aldehydes,polyacetylides, benzene, toluene, xylenes, styrene, aniline,cyclohexanone, caprolactam, propylene, butadiene, butyne diol,butandiol, C2-C4 hydrocarbon compounds, ethylene glycol, diesel fuel,diacids, diols, pyrrolidines, and pyrrolidones.

A contaminant removal zone 120 for removing one or more contaminantsfrom the hydrocarbon or process stream may be located at variouspositions along the hydrocarbon or process stream depending on theimpact of the particular contaminant on the product or process and thereason for the contaminants removal, as described further below. Forexample, particular contaminants have been identified to interfere withthe operation of the supersonic flow reactor 5 and/or to foul componentsin the supersonic flow reactor 5. Thus, according to one approach, acontaminant removal zone is positioned upstream of the supersonic flowreactor in order to remove these contaminants from the methane feedstream prior to introducing the stream into the supersonic reactor.Other contaminants have been identified to interfere with a downstreamprocessing step or hydrocarbon conversion process, in which case thecontaminant removal zone may be positioned upstream of the supersonicreactor or between the supersonic reactor and the particular downstreamprocessing step at issue. Still other contaminants have been identifiedthat should be removed to meet particular product specifications. Whereit is desired to remove multiple contaminants from the hydrocarbon orprocess stream, various contaminant removal zones may be positioned atdifferent locations along the hydrocarbon or process stream. In stillother approaches, a contaminant removal zone may overlap or beintegrated with another process within the system, in which case thecontaminant may be removed during another portion of the process,including, but not limited to the supersonic reactor 5 or the downstreamhydrocarbon conversion zone 100. This may be accomplished with orwithout modification to these particular zones, reactors or processes.While the contaminant removal zone 120 illustrated in FIG. 2 is shownpositioned downstream of the hydrocarbon conversion reactor 105, itshould be understood that the contaminant removal zone 120 in accordanceherewith may be positioned upstream of the supersonic flow reactor 5,between the supersonic flow reactor 5 and the hydrocarbon conversionzone 100, or downstream of the hydrocarbon conversion zone 100 asillustrated in FIG. 2 or along other streams within the process stream,such as, for example, a carrier fluid stream, a fuel stream, an oxygensource stream, or any streams used in the systems and the processesdescribed herein.

While there have been illustrated and described particular embodimentsand aspects, it will be appreciated that numerous changes andmodifications will occur to those skilled in the art, and it is intendedin the appended claims to cover all those changes and modificationswhich fall within the true spirit and scope of the present disclosureand appended claims.

1. A method for producing acrylic acid comprising: introducing a feedstream comprising methane into a supersonic reactor; pyrolyzing themethane in the supersonic reactor to form a reactor effluent streamcomprising acetylene; passing the reactor effluent stream to ahydrogenation reactor at hydrogenation reaction conditions to form anethylene effluent stream; passing the ethylene effluent stream to ahigher olefin processing unit to generate an effluent stream comprisingpropylene; passing the propylene effluent stream to an aldehyde reactorat aldehyde reaction conditions to generate an acrolein process stream;and passing the acrolein process stream and an oxygen stream to anacrylic acid reactor to generate an acrylic acid product stream.
 2. Themethod of claim 1 wherein the aldehyde reaction conditions includecontacting with a catalyst on a support, wherein the catalyst isselected from the group consisting of copper, Raney nickel, zinc oxide,and mixtures thereof.
 3. The method of claim 1 wherein the aldehydereaction conditions include contacting with a catalyst on a support,wherein the catalyst is selected from the group consisting of Bi, Mo,Co, Fe, and mixtures thereof, and wherein the catalyst includes analkali metal.
 4. The method of claim 3 wherein the alkali metal isselected from the group consisting of K, Na, and mixtures thereof. 5.The method of claim 1 wherein the aldehyde reaction conditions includesteam.
 6. The method of claim 1 wherein the aldehyde reaction conditionsinclude a temperature between 150° C. and 500° C.
 7. A method forproducing acrylic acid comprising: introducing a feed stream comprisingmethane into a supersonic reactor; pyrolyzing the methane in thesupersonic reactor to form a reactor effluent stream comprisingacetylene, CO and H2; passing the reactor effluent stream to an acrylicacid reactor at acrylic acid reaction reaction conditions to form anacrylic acid effluent stream.
 8. The method of claim 7 furthercomprising passing steam to the acrylic acid reactor.
 9. The method ofclaim 7 wherein the acrylic acid reaction conditions include a nickelcarbonyl catalyst.
 10. The method of claim 7 wherein the reactionconditions include a CO pressure greater than 1 MPa.